Cleaning sponge

ABSTRACT

A cleaning sponge with improved gripping for providing enhanced scouring and/or wiping ability is disclosed. In one embodiment, the cleaning sponge comprises a foam body having a side perimeter contained between a first surface and a second surface, a first outer layer of material attached to the first surface of the body, and a second outer layer of material attached to the second surface of the body. At least a portion of the side perimeter includes a recessed groove extending along a length of the foam body.

BACKGROUND

The present invention relates to a cleaning sponge. In particular, the present invention relates to a cleaning sponge having multiple layers and recesses for gripping.

Sponges useful for cleaning can be constructed from regenerated cellulose or synthetic foam. The sponges may be used alone or in combination with a scouring web secured to a surface of the sponge. Typically, sponges or scouring sponges are block shaped and to grip the sponge, the user either squeezes tightly onto the sides of the sponge or wraps his or her fingers around the block. Both of these gripping techniques impair the user's ability to effectively use the sponge. Gripping tightly onto the sponge may cause water or other liquid absorbed into the sponge to leak on to the surface being cleaned, such as a counter top. Wrapping fingers around the block cause the fingers, especially the fingernails, to be in direct contact with the surface being cleaned. Further, gripping tightly onto the body of the sponge distorts the scouring surface and the user's ability to use the large surface area of the scouring surface.

SUMMARY

A cleaning sponge with improved gripping for providing enhanced scouring and/or wiping ability is disclosed. In one embodiment, the cleaning sponge comprises a foam body having a side perimeter contained between a first surface and a second surface, a first outer layer of material attached to the first surface of the body, and a second outer layer of material attached to the second surface of the body. At least a portion of the side perimeter includes a recessed groove extending along a length of the foam body. In one embodiment, at least one of the outer layers is a cellulose sponge.

In another embodiment, a cleaning sponge comprises a scouring layer of material, a cellulose sponge, and a foam body having a side perimeter contained between a first surface and a second surface, opposite the first surface. The scouring layer of material is attached to the first surface of the foam body and the cellulose sponge is attached to the second surface of the foam body. At least a portion of the side perimeter of the foam body includes a recessed groove.

In another embodiment, a cleaning sponge consists of a fist scouring layer of material, a second scouring layer of material, and a foam body having a side perimeter contained between a first surface and a second surface, opposite the first surface. The first scouring layer of material is attached to the first surface of the foam body and the second scouring layer of material is attached to the second surface of the foam body. The side perimeter of the foam body includes recessed grooves.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a cleaning sponge.

FIG. 2 is a perspective view of a second embodiment of a cleaning sponge.

While the above-identified drawings and figures set forth embodiments of the invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of this invention.

The figures may not be drawn to scale.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of an embodiment of a cleaning sponge 100. The cleaning sponge 100 includes a body 110, a first outer layer 120, and a second outer layer 130. In the embodiment shown in FIG. 1, the material of each of the layers has been generically depicted.

The body 110 includes a first surface 112 and second surface 114, opposite the first surface 112. As shown the first surface 112 and second surface 114 are generally planar. The first outer layer 120 is secured to the first surface 112 of the body 110, and the second outer layer 130 is secured to the second surface 114 of the body 110. The body 110 separates the first outer layer 120 from the second outer layer 130.

The body 110 includes recessed grooves 116, 118. The recessed grooves 116, 118 are indented from the perimeter wall 111 of the body 110. In this embodiment, the recessed grooves 116, 118 located along opposite sides of the body 110 and extend linearly along the entire side. The recessed grooves 116, 118 provide a place to the user's fingers to rest within while gripping the sponge 100.

The body 110 comprises at least one third the thickness of the total sponge thickness. More typically, the body 110 comprises at least half the thickness of the total sponge thickness. The body 110, along with the recessed grooves 116, 118, provides a handle-like structure for allowing the user to more easily grip the sponge 100. Therefore, having a majority of the thickness of the overall sponge 100 at the body 110, further aids in a more comfortable grip in that the fingers can be in a more open and relaxed position.

The body 110 may be constructed from a variety of materials for aiding in providing a comfortable grip. The material may be relatively compliant or may be relatively rigid. The material may be solid or porous such that the body 110 may be able to hold and/or retain liquids. Exemplary materials for the body 110 include all types of foam, porous rubber, silicon, synthetics, synthetic foams, formed polyester, cellulose materials, and sponge materials. Specific exemplary materials include polyether or polyester, low or high density, small, large or twin pore sizes, closed or open cell, non-flammatory or flame retardant, flexible or semi-rigid, plain, melamine or post treated impregnated foams, and the like. Also, neoprene, natural rubber, SBR, butyl, butadiene, nitrile, EPDM, ECH, polystyrene, polyethylene, polypropylene, polyurethane, EVA, EMA, metallocene resin, polyurethane, PVC, blends of any of the above, and the like are also suitable materials. Natural sponges can be used and include those from the aquatic animal phylum Porifera, and from the dried, processed skeletons of certain species used to hold water, for example. Cellulose-based sponges can be used. Cellulose-based sponges can include those which are derived from plant products for example. More preferably, synthetic foam can be used. Synthetic sponges can be constructed of porous rubber, synthetic foam, other plastic and rubber derivatives, and the like.

The first outer layer 120 and second outer layer 130 may be formed from a variety of different materials depending on the desired function of the cleaning sponge 100. The material of the second outer layer 130 may be the same as, or different from the material of the first outer layer 120.

For wiping, suitable materials for the outer layers include woven, knitted, nonwoven or foam materials. Woven, knitted, or nonwoven materials may be made from natural, synthetic, or a combination of natural and synthetic fibers. The foam materials may be a synthetic or a cellulose-based sponge. In one embodiment, the wiping material is hydrophilic such that it is capable of holding and retaining water. Examples of hydrophilic materials include cellulose sponge, cellulose-based woven and knitted materials such a cotton, rayon, or microfiber woven and knitted materials.

In another embodiment, for wiping, a microreplicated film may be used. A microreplicated film includes a plurality of small, protruding, flexible stems. The microreplicated film is particularly effective in gathering and entangling fibrous material such as lint and hair. Further, the microreplicated film may provide a squeegee-like wiping ability over planar surfaces. Examples of microreplicated film are disclosed in U.S. Pat. Nos. 6,372,323; 6,610,382; 6,904,615; and US patent application publication 2008-0035173. The microreplicated film can have holes, perforations, or slits to allow water to pass through or be squeezed out of the body.

For scouring, suitable materials include woven, knitted, nonwoven or foam materials. Woven, knitted, or nonwoven materials may be made from natural, synthetic, or a combination of natural and synthetic fibers. The foam material may be any of the foam materials described above.

For woven materials, the looping of the weave may be angled in such a way to provide a scouring ability. For example, WO2007/067413 discloses a flat yarn with an angled loop for scouring.

A coating of resin may be applied to a portion or the entire surface of the woven, knitted, nonwoven or foam material to impart a rigidity and stiffness to the surface that can aid in scrubbing and scouring. An example of a printed resin on the surface of a substrate, such as a nonwoven, is disclosed in US patent application publication 2003/0228813. Another example of a printed resin onto surfaces such as woven, knitted substrates is disclosed in US patent application publication nos. 2003-0124935 and 2007-0212965. Other examples of suitable nonwoven materials including coatings of resins include Scotch-Brite™ Heavy Duty, Multi-Purpose, and Light Duty Scouring Pads, available from 3M Company of St. Paul Minn.

The surface of the material for scouring may be textured, including raised and recessed portion, which further enhance the scrubbing and scouring of the stiff material. Further, an abrasive particle may be included with the resin or separately applied over the resin to further enhance the scrubbing and scouring ability of the material.

The scouring material may include metal fibers or metal particles such that the scouring surface may also be suitable for polishing metal surfaces. An example of a metal fiber web is disclosed in US patent application publication 2007/0079462.

The first outer layer 120 is secured to the first surface 112 of the body 110 and the second outer layer 130 is secured to the second surface 114 of the body. A variety of attachment mechanisms may be used. The attachment mechanisms used for the first outer layer 120 and second outer layer 130 may be the same for both layers or may be different attachment mechanisms.

One attachment mechanism is by laminating to the body 110 by adhesive bonding. The adhesive may cover some or the entire surface of the first and/or second outer layer 120, 130. Depending on the materials chosen for the body 110 and the first and/or second outer layer 120, 130, needletacking, stitching, melt bonding, ultrasonic welding, or a removable attachment like hook/hook or hook/loop may be used for attachment. The attachment mechanism chosen should provide suitable durability for the intended function of the sponge 100. Further, the attachment mechanism chosen may be selected to provide fluid passage from the body to the first outer layer 120 and/or second outer layer 130. For example, a spot coating or otherwise discontinuous coating of adhesive would aid in providing fluid passage from the body 110 to the first outer layer 120 and/or second outer layer 130.

FIG. 2 is a perspective view of a second embodiment of a cleaning sponge 200. The cleaning sponge 200 includes a body 210, a first outer layer 220, and a second outer layer 230. The body 210 includes a first surface 212 and second surface 214, opposite the first surface 212. As shown the first surface 212 and second surface 214 are generally planar. The first outer layer 220 is secured to the first surface 212 of the body 210, and the second outer layer 230 is secured to the second surface 214 of the body 210. The body 210 separates the first outer layer 220 from the second outer layer 230.

In this embodiment, the body 210 includes a recessed groove 216. The recessed groove 216 is indented from the entire perimeter wall 211 of the body 210. In this embodiment, the recessed groove 216 is located around the entire body 210. The recessed groove 216 provides a place to the user's fingers to rest within while gripping the sponge 200.

In this embodiment, the body 210 is constructed from a foam. In particular, the foam is a synthetic foam such as a urethane foam. Synthetic foams are particularly well suited for the body because the foam is a flexible, compliant material that can absorb liquid. Synthetic foams are typically hydrophobic and therefore do not readily retain liquid within the structure. Therefore, although fluid is easily absorbed in the material, the fluid is also easily flushed from the hydrophobic foam. This fast flushing through the pores of the hydrophobic foam causes soap to become very sudsy as it passes in and out of the hydrophobic foam. Further, because the hydrophobic foam does not readily retain liquid within the structure, the body 210 will dry faster than a hydrophilic material such as cellulose sponge. Retaining less moisture in the body 210 may aid in less moisture being retained in the entire sponge 200 during storage. Minimizing moisture content should minimize microorganism growth within the sponge 200.

In this embodiment, the first outer layer 220 is a scouring surface and the second outer layer 230 is a wiping surface. Having opposed scouring surfaces and wiping surfaces gives the user the ability to both aggressively scrub a surface and then wipe the scoured surface clean. In this embodiment, the scouring surface is a lofty, nonwoven web, similar to a Scotch-Brite™ scour pad, available from 3M Company of St. Paul, Minn. Having the scouring surface as an independent surface with its own support structure may provide more strength and durability than if the scouring surface was integrally formed with the material of the body. For example, directly coating a resin on the body may provide a scouring surface; however, the material of the body may wear and degrade faster than a self supported scouring surface such as a nonwoven scouring pad.

In this embodiment, the wiping surface is cellulose sponge. Cellulose sponge provides a particularly unique wiping surface because cellulose sponge is a hydrophilic sponge that is capable of absorbing and retaining fluids. Therefore, when a damp cellulose sponge is wiped over a surface, large amounts of liquid are not deposited onto the surface being wiped. Further, spills of liquids can be absorbed and retained in the cellulose sponge until the cellulose sponge is transported to the sink to be squeezed.

The recessed grooves, whether as shown in the embodiment of FIG. 1 or FIG. 2, provide a gripping mechanism for the user to easily hold the sponge without squeezing or distorting the shape of the sponge. Excessive squeezing or distorting the shape will tend to release absorbed water from the sponge or may alter the shape and therefore the performance of the outer surface that is functioning as the working surface.

Use of a hydrophobic foam body with the recessed grooves at the body limits the release of liquid from the sponge onto a surface being cleaned or wiped because the hydrophobic foam has limited amounts of liquid retained within it and the recessed grooves prevent excessive squeezing of the entire sponge. Therefore, when used in combination with at least one of the outer surfaces of cellulose sponge, excess water is not passed to the cellulose sponge from within the body leaving the cellulose sponge with more absorption ability to wipe up and absorb spilled liquid.

It is understood that any variety of combination of materials may be used for the first and second outer layers. The first and second outer layers may be wiping materials, both may be scouring material, or one may be a wiping material while the other is a scouring material. Further, different materials may be used other than wiping or scouring materials. Materials may be use that polish, abrade, brush, or squeegee the surface being cleaned.

The sponge may assume any variety of outer perimeter shapes. FIG. 1 shows a sponge that is rectangular with symmetrical wavy edges. FIG. 2 shows a sponge with a peanut or hour glass shape. Other shapes include square, round, spherical, triangular, oval, heart, wavy, or bow-tie shaped. The sponges shown in FIGS. 1 and 2 are generally symmetrical in that the first outer layer and second outer layer are approximately the same thickness and the recessed groove is positioned in a midsection of the thickness of the sponge. A symmetrical shape aids in easily flipping from using the first outer surface to the second outer surface.

The sponge is sized to fit comfortably as a hand tool. In one embodiment, the sponge is less than six inches long and less than six inches wide. In one embodiment, the sponge is less than five inches thick. Generally, the body comprises at least one third of the thickness of the total sponge thickness. More typically, the body comprises at least half the thickness of the total sponge thickness. The first and second outer layers may be of the same thickness or may be of different thicknesses depending on the materials chosen for each respective layer. In one embodiment, the first outer layer is less than one inch thick and the second outer layer is less than one inch thick.

To use the sponge, the user will hold the palm of his or her hand over one of the first or second outer surfaces. The uncovered first or second outer surface is available for cleaning. Then, the user will comfortably position his or her fingers within the recessed groove. The user can comfortably hold the sponge without needing to position his or her fingers at the working surface, without distorting the working surface of the sponge, and without unnecessary squeezing of the sponge. Due to the generally symmetrical shape, the user can easily move between using the first outer surface and the second outer surface.

To make the sponge, typically the first outer layer and the second outer layer are attached to the body, either sequentially or simultaneously. Following the formation of a block, the recessed groove is then formed in to the body. Depending on the final shape of the sponge, the groove can be cut into individual hand sized sponges or it can be cut into larger sized sponge materials that are later converted into individual hand sized sponges. It is possible to form the recessed groove prior to attachment of the first and second outer layer. It is also possible to mold the body to assume a form having recessed grooves.

Although specific embodiments of this invention have been shown and described herein, it is understood that these embodiments are merely illustrative of the many possible specific arrangements that can be devised in application of the principles of the invention. Numerous and varied other arrangements can be devised in accordance with these principles by those of ordinary skill in the art without departing from the spirit and scope of the invention. Thus, the scope of the present invention should not be limited to the structures described in this application, but only by the structures described by the language of the claims and the equivalents of those structures. 

1. A cleaning sponge comprising: a foam body having a side perimeter contained between a first surface and a second surface; a first outer layer comprising a cellulose sponge attached to the first surface of the body; a second outer layer of material attached to the second surface of the body; wherein at least a portion of the side perimeter includes a recessed groove extending along a length of the foam body.
 2. The cleaning sponge of claim 1, wherein the foam body is hydrophobic.
 3. The cleaning sponge of claim 1, wherein the second outer layer is a scouring material.
 4. The cleaning sponge of claim 3, wherein the scouring material is selected from the group consisting of woven, knitted, nonwoven, foam and sponge any of which includes at least a partial resin coating.
 5. The cleaning sponge of claim 1, wherein the second outer layer is a wiping material.
 6. The cleaning sponge of claim 1, wherein the first outer layer is attached to the first surface of the body by a discontinuous coating of adhesive.
 7. The cleaning sponge of claim 1, wherein the recessed groove extends along opposite sides of the side perimeter.
 8. The cleaning sponge of claim 1, wherein the recessed groove extends along the entire side perimeter.
 9. The cleaning sponge of claim 1, wherein the body comprises at least a third of a thickness of the sponge.
 10. A cleaning sponge comprising: a scouring layer of material; a cellulose sponge; and a foam body having a side perimeter contained between a first surface and a second surface, opposite the first surface; wherein the scouring layer of material is attached to the first surface of the foam body and the cellulose sponge is attached to the second surface of the foam body; wherein at least a portion of the side perimeter of the foam body includes a recessed groove.
 11. The cleaning sponge of claim 10, wherein the scouring material is selected from the group consisting of woven, knitted, nonwoven, foam and sponge any of which includes at least a partial resin coating.
 12. The cleaning sponge of claim 10, wherein the recessed groove extends along opposite sides of the side perimeter.
 13. The cleaning sponge of claim 10, wherein the recessed groove extends along the entire side perimeter.
 14. The cleaning sponge of claim 10, wherein the foam body comprises at least a third of a thickness of the sponge.
 15. A cleaning sponge consisting of; a first scouring layer of material; a second scouring layer of material; and a foam body having a side perimeter contained between a first surface and a second surface, opposite the first surface; wherein the first scouring layer of material is attached to the first surface of the foam body and the second scouring layer of material is attached to the second surface of the foam body; wherein the side perimeter of the foam body includes recessed grooves.
 16. The sponge of claim 15, wherein the foam is cellulose sponge or polymeric foam.
 17. The sponge of claim 15, wherein the first and second scouring material are each independently selected from the group consisting of woven, knitted, nonwoven, foam and sponge any of which includes at least a partial resin coating.
 18. The sponge of claim 15, wherein at least one of the first or second scouring materials is melamine. 